Product Name:  
BOV Kompact EM Series  
BOV Kompact EM Series  
TS-0223-1XXX  
Product Description:  
Product Number:  
Document Version:  
V1.00 Rev C  
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IMPORTANT NOTES ON YOUR BOV  
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Turbosmart accepts no responsibility whatsoever for incorrect installation of this product which is potentially hazardous and can cause serious  
engine damage or personal injury.  
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The EM series BOV is designed for use as a factory replacement for a turbocharger that utilises an electronic diverter valve, this valve can be  
used on other applications as long as there is a control signal to actuate the BOV.  
Ensure the engine is cold prior to installation.  
For Standalone ECU configuration, ensure valve is not energised for indefinite periods of time as this can cause significant life detriment to the  
actuation solenoid.  
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RECOMMENDATIONS  
- Turbosmart recommends that your Blow off valve (BOV) is fitted by an appropriately qualified technician  
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KIT CONTENTS  
Please check that the following items have been provided in your EM Series BOV packaging  
Part  
Description  
Turbosmart EM Series BOV  
M6 Flange Bolts  
Use  
1
2
3
Main unit  
Mount BOV to turbocharger compressor cover  
Turbosmart sticker  
Turbosmart Sticker  
Figure 1 - Kit Contents  
TOOLS REQUIRED  
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5mm hex key  
1
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ABOUT YOUR EM SERIES BOV  
Turbosmart has developed a unique “plug and play” diverter valve (or bypass valve) upgrade for your vehicle that is currently equipped  
with an electronic diverter valve. While we have developed this unit to be as simple as possible for you to install, we have not  
compromised on performance. This unit will not leak under elevated boost pressures and will still provide you with rapid response  
ensuring that all the OEM calibration strategies are not interfered with, providing you with maximum boost performance while the  
advanced strategies of the OEM’s are retained.  
The EM series BOV is available in two configurations, Dual Port and Plumb Back. The functionality of the BOV is still the same, there  
is no performance difference between the two units, it is a personal preference if the user wishes to utilise a classic vent to atmosphere  
sound or revert all bypass gasses back into the inlet tract of the turbocharger.  
As the valve is completely controlled by the factory engine control unit, the factory diverter valve is almost silent, due to our  
construction, it is possible that your EM series will be much more audible. By being able to hear the unit actuate, occasionally the  
valve may be opening for a few seconds under the following events such as traction control, cruise control management, rapid  
gearchanges and varying throttle position changes, these are all coded as part of the torque management software in the OEM engine  
control unit, there is no adjustment available over these functions via our product. By hearing these events, it is not abnormal, it is  
completely normal for the EM series BOV to be considered “very active” as it is protecting your turbocharger from surge events or  
bypassing air for torque management purposes.  
Electronic Actuator  
Controls when the valve opens,  
Control Signal Plug  
and closes based on OEM  
Connect to OEM harness  
signal  
Flange Mounting Holes  
Bolt to turbo compressor  
cover  
Vent to Atmosphere Port  
(Only on “Dual Port” Models)  
Vents excess air to  
atmosphere  
Sealing O-Rings (Underneath)  
Ensures the valve does not leak  
compressed air  
Plumb Back Port (Underneath)  
Recirculates excess air to  
turbocharger inlet  
Plumb Back Orientation Indicator  
A flat on the flange, acts as a visual  
cue to install the BOV in the correct  
position relative to the plumb back  
pathway  
Figure 2 - EM Series BOV Overview  
2
FITTING YOUR EM SERIES BOV  
Remove the OEM diverter valve  
3
Identify turbocharger location  
1
Remove the electronic plug from the OEM diverter valve and  
unscrew the three screws in an anti-clockwise direction,  
completely remove and safely store the original mounting  
screws. The valve will likely want to fall off the mounting flange  
as you unscrew the last screw, ensure you do not drop the OEM  
valve as permanent damage may occur to the plastic.  
Identify the location of the turbocharger assembly, this is usually  
located close to the exhaust side of the engine for a typical in-  
line engine, for a v configuration engine, following the path of the  
exhaust immediately out of the head can assist you in locating  
the turbocharger assembly.  
If the turbocharger cannot be located, seek assistance from your  
local specialist.  
Observe factory plumb back recirculation path  
4
(
required if your valve has a flat)  
NOTE!  
Cosmetic engine covers may be required to be removed  
prior to the turbocharger assembly being visible.  
If your BOV has a flat featured on the flange (indicated in yellow  
below), this flat is to indicate the orientation of the plumb back  
ports relative to the factory plumb back recirculation path. This is  
to ensure maximum recirculation performance.  
CAUTION!  
The turbocharger assembly may require the vehicle to be  
raised on a hoist or jacked up and secured using vehicle  
jack stands, ensure your safety is not compromised.  
Identify OEM diverter valve location  
2
The OEM electronic diverter valve is usually located on the  
compressor cover of the turbocharger, the diverter valve  
generally is mounted with 3 or 2 bolts.  
On some vehicle applications, this diverter valve is mounted on  
the intercooler, or the charge pipe between the turbocharger  
compressor outlet and the engine throttle body.  
If the diverter valve cannot be located, seek assistance from your  
local specialist.  
NOTE!  
It may be required to remove auxiliary components to  
access the diverter valve, ensure you consult your local  
specialist or a service manual for correct disassembly  
procedures.  
Compressor Cover  
Diverter Valve  
Usually black plastic  
construction  
3
Mount your EM Series BOV  
5
Slide the EM Series BOV into the mounting flange ensuring that  
the sealing O-rings are still in place on their respective grooves.  
Once the unit is inserted into the mounting flange, the valve can  
be rotated to line up the mounting flange bolt pattern against the  
OEM mounting flange pattern, finally, screw the mounting screws  
into
CAUTION!  
Ensure the plumb back port is located correctly if there is a  
flat on your mounting flange facing the plumb back port on  
the turbocharger or diverter valve mounting assembly, this  
is to allow for effective flow from the plumb back port back  
into the recirculation path, failing to do this can cause  
compressor surge due to insufficient flow.  
Once the valve has been mounted and the screws tightened,  
connect the electrical plug into the OEM factory plug and secure  
the wiring safely away from a heat source.  
Congratulations, your EM Series BOV is installed and ready for  
use. Double check all electrical connections and mounting  
screws.  
CHANGING THE ELECTRONIC ACTUATOR  
Remove Your EM series BOV  
Remove Electronic Actuator from your EM  
series BOV  
1
2
Remove the electronic plug from the EM series BOV and  
unscrew the flange screws in an anti-clockwise direction,  
completely remove and safely store the mounting screws. The  
valve will likely want to fall off the mounting flange as you  
unscrew the last screw, ensure you do not drop the valve as  
permanent damage may occur. Ensure O-Rings are kept with  
the valve for reinstallation.  
Using a 11mm open end wrench in the flat sides of the  
solenoid, undo the actuator in an anti-clockwise direction  
when viewed from the end. Ensure the wrench is placed on  
cover.  
NOTE!  
Cosmetic engine covers may be required to be removed  
prior to the assembly being visible.  
CAUTION!  
The turbocharger assembly may require the vehicle to be  
raised on a hoist or jacked up and secured using vehicle  
jack stands, ensure your safety is not compromised.  
4
Ensure the cavity is free from debris using avoiding shifting dirt  
into the passages.  
Install New Electronic Actuator into your  
EM series BOV  
3
Ensure the O-rings on your new actuator are correctly seated  
O-Rings  
CAUTION!  
Failure to ensure O-rings are seated correctly may lead to  
cutting of an O-Ring and unexpected results from the EM  
series BOV  
Slowly insert the new actuator while turning in a clockwise  
direction to avoid tearing the O-rings  
CAUTION!  
Ensure the plumb back port is located correctly if there is  
a flat on your mounting flange facing the plumb back port  
on the turbocharger or diverter valve mounting assembly,  
this is to allow for effective flow from the plumb back port  
back into the recirculation path, failing to do this can  
cause compressor surge due to insufficient flow.  
Tighten the new solenoid into the EM series BOV ensuring the  
wrench is on the metallic portion of the solenoid.  
NOTE!  
Tightening the solenoid on the plastic cover may result in  
unrepairable damage to the solenoid.  
Once the valve has been mounted and the screws tightened,  
connect the electrical plug into the OEM factory plug and  
secure the wiring safely away from a heat source.  
Mount your EM Series BOV  
4
Congratulations, your EM Series BOV is installed and ready  
for use. Double check all electrical connections and mounting  
screws.  
Slide the EM Series BOV into the mounting flange ensuring  
that the sealing O-rings are still in place on their respective  
grooves. Once the unit is inserted into the mounting flange,  
the valve can be rotated to line up the mounting flange bolt  
pattern against the OEM mounting flange pattern, finally,  
screw the mounting screws into place securing the BOV.  
5
TROUBLE SHOOTING  
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BOV not actuating - Confirm electrical signal plug is connected appropriately, as the plugs are new, some force may be  
required to click the plug into place.  
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Valve is staying open – Confirm the valve has O-rings as they may have been dropped or lost during installation  
Boost pressure loss or lower than before - Confirm the valve has O-rings as they may have been dropped or lost during  
installation  
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Failing the above, submit a technical request to tech@turbosmart.com.au with information of your engine configuration and  
photos of installation  
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